Metal roof or wall construction



Dec. 3, 1957 J. s. REEvEs METAL ROOF OR WALL CONSTRUCTION 5 Sheets-Sheet 1 Filed March 10, 1953' Fig.4.

INVENTOR John S. Reeves ATTORNEYJ Dec. 3, 1957 J. 5. REEVES METAL ROOF 0R WALL CONSTRUCTION INVENTOR new? ATTORNEYS 5 Sheets-Sheet 2 (lo/2n; S. Reeve! Filed March 10, 1953 Dec. 3, 1957 J. 5. REEVES 2,814,999

METAL ROOF OR WALL CONSTRUCTION.

Filed March 1 o, 1953 a Sheets-Sheet s INVENTORT ATTORNEYS John, ,S. Reeves c w,7dwmwm E E E E I." E E I l E E I E E E E I I I: E 0, E E 1 E n: E w E United States Patent METAL ROOF 0R WALL CONSTRUCTION John S. Reeves, West Palm Beach, Fla. Application March 10, 1953, Serial No. 341,589 2 Claims. (Cl. 108-13) This invention relates to a wall, roof or like structure formed of parallel metal slats that are detachably interlocked with each other and with transversely extending strengthening and supporting members.

One of the objects of the invention is to provide an improved slatted structure of the type mentioned above in which the slats and transverse supporting members are assembled into an integral structure in a novel manner and without the use of nails, screws, bolts or other fasteners.

Another object is to provide an improved structure of the above mentioned type which can be assembled very easily with a minimum of time, labor and expense.

A further object is to provide an improved structure of the foregoing type wherein the adjacent parallel edges of the slats are interlocked in a novel manner to provide not only a strong mechanical connection but also Water tightness.

A still further object is to provide such an improved construction wherein the slats, although detachably assembled Without the use of fasteners, are nevertheless held tightly in place without rattling.

Still another object is to provide such a structure wherein the transverse strengthening members are provided with novel means for attaching them to supports such as vertical studding, roof rafters, and the like.

Other objects of the invention will appear more fully hereinafter as the description proceeds.

Slatted structures of the type mentioned above can be used for any suitable purpose; for example, they are suitable for use as walls, roofs, and/or partitions for houses, barns, sheds, cabanas, trucks, trailers and the like; as covers for awnings and waiting sheds and as canopies for trucks, bulldozers, tractors and other machinery; and for many other similar purposes. It will be understood that in such structures, the parallel slats are of relatively light sheet metal and that the interlocking slat structure must be connected and strengthened by means in addition to the slats themselves in order to with-- stand wind pressures, sustain roof loads, etc. In a roof structure, for example, the slats extend from the ridge pole to the edge of the roof and are supported and strengthened by intermediate transverse members properly called purlins. For convenience, this term will be used throughout the following description and claims to refer to such intermediate strengthening members, although when the structure is disposed vertically, for example, the said members may not perform all of the functions of the usual purlin.

A characteristic feature of structures embodying the invention, regardless of their size, form or purpose, is a three-way interlock formed between two adjacent edges of a pair of slats and an associated purlin at its intersection with these edges. The slats are channel-shaped, generally speaking, alternate slats facing in opposite directions and their adjacent edges being reversely curved and interlocked with one another in a manner preventing relative lateral separation but permitting relative longitudinal "ice sliding movement for purposes of assembly. The bottoms of the channels are preferably corrugated longitudinally for greater strength and stillness, but this is not necessary in all cases. The purlins may comprise flanged beams, channels, or other desired structural shapes, and are provided with notches formed in their edges the ends of which are undercut to receive the interlocked edges of the slats. Thus every other slat may be termed a bottom slat, being bottomed in one of said notches with its reversely curved edges engaged and retained in the undercut ends thereof. Each intermediate oppositely facing or top slat then has its reversely curved edges engaged in the adjacent undercut ends of two adjacent notches and interlocked therein with the reversely curved edges of the bottom slat.

Thus each pair of interlocked slat edges is retained in and by one of the undercut notched ends to form a tight three-way connection between top slat, bottom slat and purlin and an integral structure without the use of any of the usual types of fasteners. For purposes of assembly or disassembly, the individual slats are slid endwise into and out of place, and it will be seen that by properly coordinating the dimensions of the slats and notches, lateral shifting or displacement of the slats is prevented. Also the undercut ends of the notches hook around and secure the slats tightly to the purlins; the fit of the interlocked edges in the undercut notch ends is preferably tight enough to avoid undue rattling or other noise. Such a structure is watertight under normal conditions of use except Where covered by standing water; in this event special provisions are desirable to prevent leakage as described below.

Several embodiments of the invention are illustrated by the accompanying drawings, but it is to be expressly understood that said drawings are for purposes of illustration only and are not to be construed as a definition of the limits of the invention, reference being had to the appended claims for this purpose.

In the drawings,

Fig. 1 is a perspective view showing a section of slatted structure embodying the invention;

Fig. 2 is a cross section through a structure such as illustrated by Fig. 1, Fig. 2 also showing a preferred form of connection to a roof rafter, vertical stud, or the like;

Fig. 3 is a partial side view of Fig. 2;

Fig. 4 is a detail similar to Fig. 2 but showing a difierent type of stud or rafter;

Fig. 5 illustrates a modification in which two structures of the type shown in Fig. l are arranged back to back and connected together to form a wall construction;

Figs. 6-14 inclusive show a combined storm shutter and awning embodying the invention, Fig. 6 being a vertical sectional view of the construction when in use as an awning;

Fig. 7 being a detailed View taken on the line 3 -4 of Fig. 6;

Figs. 8-10 inclusive comprising detailed views of parts of the awning construction;

Fig. 11 being a view of the inside of the construction when in use as a storm shutter; and

Figs. 12-14 showing additional details of the construction.

Fig. I shows in perspective a section of a slatted struc* ture including top and bottom slats and a purlin. By way of example, the slats in this section are shown slightly curved or arched as would be the case in the root of a Quonset hut or in the top of the awning shown in Figs. 6-14. It will be understood, of course, that for many applications such as fiat walls and flat sloping roofs, such curvature of the slats is omitted. Also the purlin is shown as a channel-member, this shape being preferred in most cases, but any other desired structural shape can be employed.

Every other slat 1 in Fig. 1 is a bottom slat, so-called because it is bottomed in the notches in the purlin as mentioned above and as described hereinafter. Similarly every other slat in alternation with said bottom slats is a socalled top slat 2. Preferably and as shown, both the bottom slats and the top slats are corrugated longitudinally, although corrugation can be omitted if flat surfaces are desired.

The marginal portions of each top slat 2 are reversely curved, being turned through approximately 180 so as to extend back inwardly toward the center line of the slat. Preferably two sharp turns are made at 90 angles to provide a fairly tight and accurate fit between the interlocked edges of the top and bottom slats. Thus the edges of each top slat are turned through 90 at the bends 3 to provide perpendicular side walls 4, and through a further 90 at the bends 5 to provide reversely curved flanges 6.

The marginal portions of each bottom slat 1 are also reversely curved and are preferably shaped to correspond with and fit closely and accurately in the edges of the top slats when the slats are interlocked. As shown, therefore, these marginal portions are turned through 90 at the bends 7 to provide perpendicular side walls 8, and through a further 90 at the bends 9 to provide reversely curved flanges 10. The height of the perpendicular wall portions 8 is preferably such that the distance between the flanges 1d and the bodies of the slats is substantially equal to the thickness of the flanges 6 of the top slats, said flanges 6 thus fitting closely between them. The height of the corresponding perpendicular walls 4 of the stop slats is greater, however, in order to accommodate the hook-like retainers formed by the undercut notches as described hereinafter. In some cases, moreover, the walls 4 are made still higher and the extreme edges of the bottom slats are turned back through 90 at the bends 11 to provide perpendicular flanges 12 accommodated in the extra space thus provided. The purposes and functions of this arrangement will be set forth below.

It will thus be seen that the slats are channel-shaped, generally speaking, with alternate slats facing in opposite directions, and that when the reversely curved edges of the alternate slats are interlocked, the slats form a continuous wall surface.

The third element of the combination comprises a transversely extending notched purlin. This purlin is preferably channel-shaped as stated above, thus having a bottom 13 and parallel side walls 14, the open side of the channel being turned toward the slats. The parallel edges of the side walls 14 are then provided with corresponding series of aligned undercut notches as clearly shown in Fig. 1. The length of the bottom edges 15 of the notches is approximately equal to the width of the bot-tom slats between the perpendicular side walls 8, and the depth of the undercut ends 16 of the notches is approximately equal to the thickness of the reversely curved edges of the bottom sla-ts (i. e., about three times the thickness of the slat material). Thus the projecting ends 17 of the purlin edges extend over the flanges 10 of the bottom slats and form hook-like retainers for the interlocked edges of the top and bottom slats. When the top and bottom slats are assembled with the purlin, moreover, these pro jecting ends 17 extend into the reversely curved edges of the top slats, being received in the spaces provided in the perpendicular side walls 4 thereof. Preferably the length of the edge portions 18 of the side walls of the purlin between the notches are approximately equal to the distance between the perpendicular side walls 4, or between the juxtaposed flanges 12 of the bottom slats where these are provided.

It will be seen, therefore, that there is :a secure and tight interlock between the three elements, namely, the top slats 2, the bottom slats 1, and the purlin or purlins. The assembly is made by sliding the slats endwise relative to one another and to the purlin, and the structure can be disassembled in the same manner if necessary. The

4 purlin strengthens and supports the slatted structure and gives it rigidity against lateral forces. The engagement of the interlocked edges of the slats in the undercut ends of the purlin notches ensures a tight rigid structure. In this connection it is of advantage to employ channelshaped purlins or the equivalent thereof because in this way each pair of interlocked slat edges is retained by each purlin at two longitudinally spaced points.

As stated above, the perpendicular flanges 12 of the bottom slats are not always necessary. They are of advantage, however, in that they may project slightly above the top edges 18 of the purlin, whereupon their edges form slideways for the top slats 2 and excessive frictional contact of the corrugated slats with the purlin edges 18 is prevented. When the slatted structure isused as a canopy or roof, moreover, these flanges 12 contribute materially to the water tightness of the construction. It will be seen that the bottom slats 1 provide channels bounded by the side walls 4 of the top slats in which water can accumulate. Even with a sloping roof, this accumulation can build up to a substantial depth in the case of a heavy downpour of rain. The flanges 12 act as dikes, increasing the depth to which such accumulation can build up without overflowing and thus minimizing the danger of leakage through the interlocked edges of the slats.

The use of channel-shaped purlins is also of advantage when it comes to the attachment of the slatted structure to frame studs or rafters. For this purpose the bottom 13 of the purlin is provided with suitably spaced longitudinal slots 19 as shown in Fig. 1, and suitable attaching members such as the brackets 20 (shown in dotted lines in Fig. 1) are mounted adjustably in these slots by suitable means such as bolts 21 having rectangular heads 22 that are nonrotatably engaged between the side walls 14 of the purlin and nuts 23 on their ends. Before assembling the slats with the purlin, the bolts 21 are placed in the slots 19 where desired. After the slatted structure of the desired size has been assembled, it is applied as a unit to the framework and the brackets 20 are adjusted into engagement with the frame studs or rafters, after which the nuts 23 are tightened to secure the brackets in their adjusted positions. Fig. 2 illustrates this method of attachment of a slatted structure to a supporting member 24 in the form of an I-beam which may, for example, constitute a rafter supporting a slatted roof. Fig. 2 shows two brackets 20 adjustable in a single slot 19, although if desired separate slots can be employed. As shown, the brackets 20 have been moved into engagement with opposite edges of the flanges of the I-beam 24 and then looked in these positions by tightening the nuts 23 as described above. Any desired connection can then be made between the brackets 20 and the I-beam; as shown, a bolt 25 passes through both brackets and through the web of the I-beam 24, being secured by a nut 26.

A similar arrangement can be employed in the case of wood studs or rafters such as shown in Fig. 4. In this case the brackets 20 may be secured to the opposite sides of a wood supporting member 27 by means of nails 28.

In some cases it may be desired to provide a slatted wall construction having slats on both exposed sides with concealed purlins. The slatted structure shown in Fig. 1 and described above lends itself readily to this result as illustrated in Fig. 5, where two such slatted wall structures are shown facing in opposite directions and having correspondingly arranged purlins, the bottoms of these purlins engaging one another and being connected by suitable means such as a bolt 29 and nut 30.

Figs. 6-14 inclusive illustrate the further use of a slatted structure of the above type in a combined awning and storm shutter. As shown in Figs. 6 and 11, for example, bottom and top slats l and 2 respectively are assembled together with a series of notched purlins 13 to form an arched slatted structure as described above, this structure being the top of the awning (Fig. 6) and the external surface of the storm shutter (Fig. 11). For shifting from one position to the other this slatted structure is stiffened in any suitable manner and pivoted along its horizontal upper edge to the window frame 31 or other suitable part of the building to swing between the two positions. For example, arcuate side bars 32 (Figs. 6 and 7) extend between the ends of the purlins 13, following the curvature of the slats and being secured by screws 33 or the like to flanges 34 bent outwardly from the side walls of the purlins. Also straight chord members 35 connect the ends of the uppermost and lowermost purlins, being provided for example with suitable end flanges (Fig. 7 and 12) connected to the purlins by screws 36. The hinges are preferably located at the upper corners of the awning and attached both to the chord members 35 and to the uppermost purlin 13. As shown in Figs. 12 and 13, the hinge members 37 are secured to the bottoms of the purlins by screws 38, and are provided with flanges 39 secured to the chord members 35 by means of screws 40. The hinges are carried by hinge pins 41 mounted in brackets 42 secured to the building structure 31 in any suitable manner. A shield 43 (Fig. 6) may be employed to cover the small opening between the top of the slatted structure and the building wall.

Preferably the segmental spaces between the arcuate roof and the chord members 35 are closed or substantially closed to form awning sides and also to enclose the window when the awning is lowered to act as a storm shutter. In the form shown, these side closures are provided by a plurality of vertical slats 44 spaced somewhat apart and extending between the arcuate side bars 32, to which they are secured by screws 45, and the chord members 35, to which they are secured by screws 46. Preferably the slats 44 have reversely curved edges 47 and the chord members 35 are provided with undercut notches 47 to receive these edges. Because of these reversely curved edges, the passages between adjacent slats have substantial depth and wind and rain cannot penetrate the protected space except in directions approximately parallel with the building wall.

It may also be desirable for the vertical sides of the awning to extend downwardly below the chord members 35, in which case the extensions are made to fold inwardly when the awning is lowered to act as a storm shutter. The drawings illustrate a construction in which such side flaps are suspended pivotally from the chord members 35. Each flap comprises a top support 48 parallel to the associated chord member 35, a plurality of vertical slats 49 corresponding and arranged similarly to the vertical slats 44 mentioned above, and suitable horizontal stiffening means indicated generally at 50, 51 and 52. These parts are suitably united into integral flap structures. Preferably each top support 48 is similar to a chord member 35, being provided with undercut notches 53 (Fig. 8) adapted to receive the reversely curved edges 54 of the slats 49. The lower end of each support 48 terminates in a flange 55 which may be inserted under the reversely curved edge 54 of the last slat 49 and secured thereto by a screw 56. The horizontal stitfeners 50 and 51 are preferably of the construction shown in Fig. 9, each comprising half channels overlapping and connected together by means of screws 57. The edges of these half channels are notched at 58 in a manner similar to the top member 48, but their unnotched portions 59 are preferably turned at right angles so as to engage under the reversely curved edges 54 of the slats. By removing the screws 57 and displacing the half channels longitudinally relative to one another, the spacing of the slats 49 can be accurately determined and the slats fixed in position. The stiffener 52 may be of the same type, but preferably comprises simply a flat bar connected by screws 60 to the reversely curved edges 54 of the slats.

These side flap structures are suitably pivoted by hinges connecting each top member 48 with its parallel chord member 35. As shown, three hinges are spaced suitably along these parallel members, the details of the hinges being shown in Figs. 10 and 12. The hinge leaves 61 are connected to the tops of supports 48 by suitable means such as screws 62 and are hanged by pins 63 to shorter hinge leaves 64 which are connected to the chord members 35 by screws 65. The members 35 and 48 normally occupy the same vertical plane (Figs. 6 and 10), but when the flaps are swung inwardly to the position shown in Figs. 11 and 12, they are completely inside the chord members 35 and do not interfere with the desired close engagement of these members with the sides of the buildmg.

Any suitable means can be employed for holding the structure in the awning position shown in Fig. 6 or in storm shutter position shown in Fig. 11, but preferably the same fastening devices on the side of the building are arranged to engage separate fasteners on the awningshutter structure in these different positions. As shown in Fig. 14, for example, the chord members 35 carry fastener members 66 which are secured thereto by means of screws 67 and are provided with eyes 68 adapted to be pinned to brackets 69 (Fig. 6) secured to the building wall when the structure is lowered to its shutter position. The radial distance of the fastener 66 from the hinge axis 41 is preferably equal to the radial distance of the end of the horizontal stiffener 51 from said axis. Accordingly similar fasteners 70 having eyes 71 project from the ends of the members 51 and are connected to the brackets 69 by means of pins 72 when the structure is in its awning position.

While several embodiments of the invention have been described and illustrated in the drawings, it is to be understood that these embodiments are by way of example only and that the invention has many other uses and applications, some of which have been mentioned above and others of which will be apparent to those skilled in the art. It will be understood further that various changes can be made in the form, details of construction and arrangement of the parts in using the invention for various purposes and under various conditions, without departing from its spirit. Reference should therefore be had to the appended claims for a definition of the limits of the invention.

What is claimed is:

1. A slatted structure for roofs and the like comprising a plurality of parallel metal slats arranged as alternate top and bottom slats with overlapping edges, each edge of each slat having a reversely curved flange interlocking with the overlapping reversely curved flange, the distance between said bottom slats and their flanges being approximately equal to the thickness of the interlocking flanges of the top slats, the distance between said top slats and their flanges being substantially greater than the thickness of the interlocking flanges of the bottom slats, to provide a space between each top slat and each adjacent bottom slat flange, a purlin extending transversely across said slats and having a series of notches with undercut ends, the bottoms of the notches having a. length substantially equal to and extending beneath the entire width of said bottom slats and the notches being spaced to receive said bottom slats bottomed in said notches, the projections formed by the undercut ends of the notches each extending over a pair of interlocking flanges and into and substantially filling the aforesaid spaces, whereby escape of the slats from the notches is prevented and they are restrained against all but endwise movement, and the edge portions of the purlin between adjacent notches connecting the upper ends of said projections and forming continuous members of a length substantially equal to the distance between the edges of the top slats and each extending transversely across and beneath the entire Width of a top slat.

7 2. A slatted structure as defined in claim 1, the total thickness of the reversely curved flanges of the bottom slats being substantially equal to the depth of the undercut ends of said notches, thereby providing an anti-rattling connection.

References Cited in the file of this patent UNITED STATES PATENTS 1,536,977 Skipworth May 5, 1925 

